CN1253621C - Method for producing non-woven fabrics - Google Patents

Method for producing non-woven fabrics Download PDF

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Publication number
CN1253621C
CN1253621C CNB001011669A CN00101166A CN1253621C CN 1253621 C CN1253621 C CN 1253621C CN B001011669 A CNB001011669 A CN B001011669A CN 00101166 A CN00101166 A CN 00101166A CN 1253621 C CN1253621 C CN 1253621C
Authority
CN
China
Prior art keywords
supporting member
bondedfibre fabric
bossing
pattern
fabric
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CNB001011669A
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Chinese (zh)
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CN1277274A (en
Inventor
W·A·詹姆斯
W·G·F·凯利
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johnson and Johnson Consumer Inc
Original Assignee
McNeil PPC Inc
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Filing date
Publication date
Application filed by McNeil PPC Inc filed Critical McNeil PPC Inc
Publication of CN1277274A publication Critical patent/CN1277274A/en
Application granted granted Critical
Publication of CN1253621C publication Critical patent/CN1253621C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B23K26/382—Removing material by boring or cutting by boring
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H18/00—Needling machines
    • D04H18/04—Needling machines with water jets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
    • B23K2103/38—Fabrics, fibrous materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

A topographical support member and a method of forming a topographical support member for use in producing nonwoven fabrics with raised portions, especially intaglio and slub type portions. The topographical support member comprises a body having a top surface including a first micro-sized topographical pattern and a pattern of apertures extending through the body. At least one macro-sized region recessed below the top surface is provided. The micro-sized pattern produces a background portion of the fabric and the macro-sized recessed regions produce the raised portions of the fabric. Multiple levels may be provided in the macro-sized region to produce multiple level raised portions. The invention also relates to method for producing the no-spin fabric and apparatus using the same.

Description

Produce the method for bondedfibre fabric and used equipment thereof
The application be that September 16 nineteen ninety-five, application number are 95117781.8 the applying date, denomination of invention divides an application for the application for a patent for invention of " manufacturing has the device of the bondedfibre fabric of bossing ".
Technical field
The equipment that the present invention relates to produce the method for bondedfibre fabric and make bondedfibre fabric.
Background technology
For centuries, just conventional fabrics is decorated, and by embroidery and other needling process modify its surface texture, originally, this technology is to finish by dull hand labour, sews on fine and close needle tracking hard so that produce the effect that adds up in a certain zone on base fabric according to a certain specific pattern.Gained has the product of a base cloth, and it comprises according to a certain pattern woven or knitting line or yarn, piles up formed bossing by line according to certain loop bonding pattern, and the overall pattern that is determined by size, shape, orientation and the position of these bossings.Though its style is abundant, these products are difficult to make and the producing cost costliness.
Most bondedfibre fabrics are flat, and outward appearance is flat.Under certain conditions, bondedfibre fabric is carried out embossing or stamps certain pattern, to produce certain visual effect.In other cases, bondedfibre fabric produces a kind of complete pattern in its manufacture process.Bondedfibre fabric with the global pattern of self can be divided into two classes:
1) porose fabric-by in the hole or the style fabric that constitutes of circumocular bunched fiber fragment network; Or
2) weight style fabric-by fiber being concentrated on higher basis weight zone, the fabric that opacity was obtained improving its low basis weight zone that has higher translucence relatively.
It is very important distinguishing basis weight and density." basis weight " is meant the weight of unit are fiber web or fabric or its specific part.Have earlier at some that basis weight is also referred to as " area density " in the patent." density " speech is meant the weight of unit volume fiber web or fabric or its specific part." density " be otherwise known as " bulk density " arranged earlier in the patent at some.Typical embossed technology can produce the higher density district under the situation that does not change basis weight.Density is uniformly kept substantially in the zone that the technology of traditional nonwoven formation decorative pattern can produce various basis weight simultaneously.
The existing bondedfibre fabric of being produced by the above-mentioned known technology that forms decorative pattern does not have not clearly, the tangible bossing of boundary, therefore is difficult to see desirable pattern.In addition, the size of the bossing of existing embossing nonwoven fabric is unsettled, when stressed, and its lug boss branch forfeiture three-dimensional structure when it is handled or launders.
Be used to make the known several years of technology of bondedfibre fabric.In a kind of technology, fibrous batt or net utilize current to handle, and its fiber is intertwined each other, and some intensity are provided in batts.The certain methods that is used to handle fibrous batt improve.Attempt to reproduce the certain physical characteristics and the outward appearance of bondedfibre fabric by this way.
US, 5,098,764 and 5,244,711 have disclosed a kind of supporting member that uses in a kind of method of producing bondedfibre fabric.This supporting member has structure and a series of aperture of a resemblance.In this technology, the initial net of fiber is positioned on the supporting member as profile.Supporting member and fiber web thereon are typically the injection of water through the excess pressure fluid, and the injection of water produces fiber and twines, and make fiber produce entanglement mutually on specific pattern according to the profile of supporting member.
Critical on the structure of resulting bondedfibre fabric in resemblance on the supporting member and pattern of apertures.In addition, at the new fiber of arranging of fluid jet and when twining its fiber in its new arrangement, supporting member must have enough structural integrities and intensity with the supporting fiber web, thereby stable fabric is provided.Supporting member not necessarily will be subjected to any sizable distortion under fluid jet power.Equally, supporting member must be useful on the device of removing a large amount of relatively fluids that tangles, and fibroreticulate to prevent " flooding ", its a large amount of relatively entanglement fluid will influence effective winding.General supporting member comprises some draining apertures, and must there be enough little size in these holes to keep fibroreticulate integrality and to prevent that fiber is by forming the loss on surface.In addition, supporting member should essentially no burr, hook or influence be from being wound the similar irregularity that fabric is removed.Simultaneously, supporting member must be such: the fiber on the processed fiber web under the effect of fluid jet, can not be flushed away.
Summary of the invention
The present invention relates to the method for profile supporting member and this supporting member of manufacturing.Described profile supporting member can be used in the manufacturing bondedfibre fabric, and this bondedfibre fabric has fiber background part at the one mask, and is protruding pars fibrosa at its another side.Two types bossing can be arranged.The basis weight of the first type of bossing background basis weight partly with this bondedfibre fabric substantially is identical.The basis weight of second type of bossing is greater than the basis weight of its background part.
One type bondedfibre fabric with supporting member made of the present invention comprises background part and at least one bossing.This background partly is positioned at and constitutes first face of described bondedfibre fabric.The bossing of described bondedfibre fabric is located on second also parallel with it on first face face.This bossing partly links to each other with background by a fiber transition region.In this special bondedfibre fabric, the basis weight of the bossing basis weight with the background part substantially is identical.The density of background part is also identical substantially with the density of bossing.The bossing that its basis weight is identical with the basis weight of background part substantially is also sometimes referred to as " intaglio " part.
Bondedfibre fabric with another type of supporting member made of the present invention also comprises background part and at least one bossing.Identical with first kind of bondedfibre fabric situation, background partly is positioned at and constitutes first face of described bondedfibre fabric, and bossing then is located on second plane on first plane and in parallel.Identical with the situation of first kind of bondedfibre fabric, bossing links to each other with this bottom by a fiber transition region.But, in the situation of second type bondedfibre fabric, the basis weight of bossing is greater than the basis weight of background part.The density of the second kind of bondedfibre fabric bossing density with the background part substantially is identical.Its basis weight is called as " ring " part sometimes greater than the bossing of the basis weight of background part.
Bondedfibre fabric with the another kind of type of supporting member made of the present invention comprises background part, at least one first bossing and at least one second bossing.Identical with the situation of above-mentioned first kind and second kind bondedfibre fabric, background partly is positioned at and constitutes first face of bondedfibre fabric.First bossing is located on second face also in parallel on first face.Similarly, second bossing also is located on second face also in parallel on first face.Each first and second bossing all passes through a fiber transition region and partly links to each other with background.In this third bondedfibre fabric, the basis weight of first bossing basis weight with the background part substantially is identical, and the basic weight of second bossing is greater than the basic weight of background part.In other words, in the bondedfibre fabric of the third type, bondedfibre fabric has one or more first bossings that is called as " intaglio " part sometimes, has one or more to be called as second bossing of " ring " sometimes.First bossing and second bossing are also nonessential in the same plane; Order is anti-, and first bossing can be positioned on the plane on the plane of background part, and second bossing can be positioned on the plane on the plane of first bossing.
Use profile supporting member of the present invention in the process of producing bondedfibre fabric, the fiber web of fiber web or layer or slight entanglement is placed on the profiled sheeting or profile supporting member of a porous, it comprises a flat basically bottom surface, has the depressed area that at least one obviously departs from the broad of profiled sheeting bottom surface on the bottom surface.Usually, described supporting member comprises a plurality of depressed areas, is the concave form in the predetermined arrangement, produces the pattern of desirable bossing by it on bondedfibre fabric.The fluid force that the liquid of water is streamed is applied to pristine fibre net or fibrolaminar upper surface.At first, this fluid force original fiber web " molded " on three-dimensional supporting member; Along with applying continuing of fluid force process, fiber kink and strand are around together, to produce a kind of bondedfibre fabric that comprises the bossing of background part and one or more mutual alignment constancies.
In another embodiment, the profile supporting member has a narrower sunk area that departs from flat basal surface of forming board.
The method that the present invention relates to be used to produce the profile supporting member of bondedfibre fabric and form the profile supporting member with bossing.Supporting member of the present invention comprises a main part with upper surface, comprises the first minute sized profile pattern and the many apertures that pass its thickness.Main part comprises that also at least one is positioned at the large-sized zone under the described upper surface.The background part of microsize pattern generating bondedfibre fabric.The large scale zone produces shape and the corresponding to fabric bossing of the degree of depth with the large scale zone.The large scale sunk area preferably has the profile pattern the same with the supporting member upper surface, yet these zones can have different patterns or there are not pattern.In addition, the large scale zone can be included in the first type surface of depression first degree of depth under the upper surface and the subsurface that one or more cup depth is different from first degree of depth.For example, can provide a subsurface around first type surface, its cup depth is positioned under first degree of depth.And have substantially cross-sectional width or diameter less than the first type surface width.
The profile pattern that constitutes the upper surface of supporting member is preferably made by laser boring technology.The laser boring method produces many protruding peaks, trench and aperture on the upper surface of supporting member.Formed by laser ablation method, the large scale zone has than the bigger cross-sectional width of repetition interval that repeats pattern.
Description of drawings
Figure 1A be to use supporting member of the present invention the plan view from above of the bondedfibre fabric that can make;
Figure 1B be to use supporting member of the present invention another bondedfibre fabric that can make;
Fig. 1 C be to use supporting member of the present invention the plan view from above of the third bondedfibre fabric that can make;
Fig. 2 is to use supporting member of the present invention and the bondedfibre fabric part microphoto made;
Fig. 2 A is the cross-sectional perspective view of being cutd open along 2A-2A line among Fig. 2;
Fig. 2 B is the cross-sectional perspective view of being cutd open along 2B-2B line among Fig. 2;
Fig. 3 is the cross section microphoto that is cutd open along 2A-2A line among Fig. 2;
Fig. 4 is the cross section microphoto that is cutd open along 4-4 line among Fig. 2;
Fig. 5 amplifies later cross sectional view with the high power of one type of bossing on the bondedfibre fabric of supporting member made of the present invention;
Fig. 6 is with second type the plane microphoto of bossing on the bondedfibre fabric of supporting member made of the present invention;
Fig. 7 is the cross section microphoto that is cutd open along 7-7 line among Fig. 6;
Fig. 8 is the idealized schematic diagram of sectional view shown in Fig. 7;
Fig. 9 is to use supporting member of the present invention to make the block diagram of the processing step of bondedfibre fabric;
Figure 10,11 and 12 is to use supporting member of the present invention to produce the schematic diagram of three kind of means of bondedfibre fabric;
Figure 13 is the part sectional perspective view of profile supporting member that is used to produce the background part of bondedfibre fabric;
Figure 14 A is the generalized section of a kind of sunk area of form on the profile supporting member of the present invention;
Figure 14 B is the generalized section of sunk area multi-form on the profile supporting member of the present invention;
Figure 15 is the schematic cross-section of the bondedfibre fabric made of the supporting member of Figure 14 B;
Figure 16 is the schematic representation of apparatus that is used for production profile supporting member of the present invention;
Figure 17 a is used for producing being used for the pattern dot chart of supporting member of bondedfibre fabric 10C of production sketch 1C;
Figure 17 b is the dot chart after square district 301 high powers among Figure 17 a are amplified.
Referring to accompanying drawing, Figure 1A is to use the plan view from above of a kind of bondedfibre fabric of supporting member made of the present invention.Bondedfibre fabric 10A comprises that background part 12 and at least one constitute first bossing 16 of one.In Figure 1A, three lug bosses fractal as letter " J ", " S " and " K ".Bondedfibre fabric 10A comprises the fiber of some staple length, and these fibers can be cotton fiber, artificial fibre or polyester fiber or their blended fiber.Background part 12 is positioned at and constitutes first plane of bondedfibre fabric 10A.First bossing 16 is located on the plane also in parallel on first plane.First bossing 16 links to each other with background part 12 by fiber transition region (will be described in detail hereinafter).In the bondedfibre fabric 10A of Figure 1A, the basic weight of first bossing 16 is identical with the basic weight of background part 12.The density of first bossing 16 density with background part 12 substantially is identical.
Referring to Figure 1B, it shows the bondedfibre fabric of the another kind of type of using supporting member manufacturing of the present invention.Bondedfibre fabric 10B is made by the fiber of some staple length.Second bossing 18 that it has background part 12 and becomes one, in plan view from above, it is rectangular usually.10A is the same with bondedfibre fabric, and this basal surface 12 of bondedfibre fabric 10B is positioned at and constitutes first plane of bondedfibre fabric 10B.10A is the same with bondedfibre fabric, and second bossing 18 on the bondedfibre fabric 10B also is to link to each other with this basal surface 12 by fiber transition region (will be described in detail hereinafter).The basic weight of second bossing 18 on the bondedfibre fabric 10B is greater than the basic weight of coupled background part 12.Obviously, first bossing 16 of bondedfibre fabric 10A has the basic weight identical with background part 12, and the basic weight of second bossing 18 of bondedfibre fabric 10B is then different with the basic weight of its background part 12.
Plan view from above shown in Fig. 1 C is to use the another kind of bondedfibre fabric of supporting member manufacturing of the present invention.Similar with 10B to bondedfibre fabric 10A, bondedfibre fabric 10C is made by the fiber of some staple length.Bondedfibre fabric 10C has a background part 12 that is positioned at and constitutes this bondedfibre fabric first plane, and it is identical with bondedfibre fabric mentioned above in this respect.Bondedfibre fabric 10C comprises first bossing 16 shown in the letter among Fig. 1 C " J ", " S " and " K ".Bondedfibre fabric 10C also has second bossing 18 that comprises three letters " J ", " S " and " K ".First bossing 16 on the bondedfibre fabric 10C is equivalent to first bossing 16 on the bondedfibre fabric 10A.Second bossing 18 on the bondedfibre fabric 10C is equivalent to second bossing 18 on the bondedfibre fabric 10B.First bossing 16 that is appreciated that bondedfibre fabric 10C has the basic weight identical substantially with background part 12.On bondedfibre fabric 10C, background part 12, first bossing 16 and second bossing 18 have identical substantially density to the basic weight of second bossing 18 greater than the basic weight of background part 12 on the other hand.
In each case, the background part 12 of bondedfibre fabric 10A, 10B and 10C all is the same.Described background part 12 has similar pattern and outward appearance through compiling, and but, should be known in that the background part can have different patterns and outward appearance.With regard to bondedfibre fabric 10A, first bossing 16 has identical similar pattern and outward appearance through compiling with background part 12.Similarly, second bossing 18 of bondedfibre fabric 10B has identical with background part 12 similar to unofficial sight.At last, background part 12, first bossing 16 and second bossing 18 of bondedfibre fabric 10C all have identical similar to compilation case and outward appearance.But, first bossing 16, second bossing 18 that should be appreciated that bondedfibre fabric 10C also can have different patterns and outward appearance with background part 12.
Fig. 2 is the microphoto (plan view from above) after bondedfibre fabric 10D part is amplified 15 times, and it is similar to the bondedfibre fabric 10A among Figure 1A.Bondedfibre fabric 10D comprises similar background part 12 and first bossing 16 that has similar through the compilation case equally through compiling.Should be understood that seen in Figure 2 only is the part of first bossing 16.First bossing 16 links to each other with background part 12 with 24 by fiber transition region 22.By seeing referring to Fig. 2, fiber transition region 22 stretches at a side along continuous straight runs of first bossing 16, and described horizontal direction is the machine direction of traversing of bondedfibre fabric 10D.Fiber transition region 24 longitudinally stretches at the opposite side of first bossing 16, and described is the machine direction of bondedfibre fabric 10D vertically.Fiber transition region 22 is converged with corner 23 places of 90 ° of angles at first bossing 16 with fiber transition region 24.Fiber transition region 22 is identical substantially with 24 fibre structure.Just as mentioned before, the basic weight with background part 12 is identical substantially for the basic weight of first bossing 16.
Fig. 2 A is the schematic diagram of bondedfibre fabric 10D, and the microphoto of its upper surface as shown in Figure 2.Fig. 2 A is the perspective cross-sectional view that the 2A-2A line along Fig. 2 is cutd open, and it helps to understand the fibre structure of bondedfibre fabric 10D.Referring to Fig. 2 A, bondedfibre fabric 10D has the fibrous background part 12 and first bossing 16, and they all are made into similar style through compiling.First bossing 16 is linked to each other with background part 12 by the fiber transition region 24 that the machine direction along fabric 10D stretches.Fiber transition region 24 comprises a few pars fibrosa 30 and a multi-fibre district 32.Few pars fibrosa 30 comprises some fiber fragment bundle 30a, and 30a forms some hole 30b in fiber transition region 24 by these fiber fragment bundles.The fiber fragment of forming fibre bundle 30a is the height parallelization, and some fiber fragment is the twisting shape in bundle.Most of fibre bundle 30a twists, and is to rely on self twisting.
Multi-fibre district 32 comprises some obviously along the vertical direction of figure, the fiber fragment that promptly stretches with the corresponding direction of the machine direction of bondedfibre fabric 10D.The end of these fiber fragments can be seen in Fig. 2 A, represents with 26.The basic weight of few pars fibrosa 30 is lower than the basic weight in multi-fibre district 32, but also is lower than the basic weight of the background part 12 and first bossing 16.The basic weight in multi-fibre district 32 is greater than the basic weight of the background part 12 and first bossing 16.The fibre bundle 30a of few pars fibrosa 30 is usually perpendicular to fiber transition region 24 orientations.And the fiber fragment that constitutes multi-fibre district 32 is orientated along the longitudinal direction of fiber transition region 24 usually.
Fig. 2 B is another schematic diagram of expression bondedfibre fabric 10D.Fig. 2 B is the cross-sectional perspective view of 4-4 line among Fig. 2.Referring to Fig. 2 B, first bossing 16 links to each other with background part 12 by the fiber transition region 22 that stretches along the phase machine direction perpendicular to bondedfibre fabric 10D.Fiber transition region 22 comprises a few pars fibrosa 27 and a multi-fibre district 28, and is similar with multi-fibre district 32 to few pars fibrosa 30 of above-mentioned fiber transition region 24 respectively.Few pars fibrosa 27 comprises some fiber fragment bundle 27a, and forms some hole 27b by these fiber fragment bundles 27a in fiber transition region 22.The fiber fragment that constitutes fibre bundle 27a is the height parallelization, and some fiber fragment wherein is the twisting shape in bundle.Minority fibre bundle 27a be twisting and be to rely on self twisting.This structure situation with few pars fibrosa 30 of above-mentioned fiber transition region 24 is opposite, and there, most of fibre bundle 30a twist, and is to rely on self to twist.Multi-fibre district 28 comprises some horizontal directions along Fig. 2, i.e. the fiber fragment that stretches with the corresponding direction of the cross machine of bondedfibre fabric 10D.In Fig. 2 A, can see the end of these fiber fragments, represent with 29.The basic weight of few pars fibrosa 27 is lower than the basic weight in multi-fibre district 28, and also is lower than the basic weight of the background part 12 and first bossing 16.The basic weight in multi-fibre district 28 is greater than the basic weight of the background part 12 and first bossing 16.The fibre bundle 27a that few pars fibrosa is 27 li is usually perpendicular to fiber transition region 22 orientations.And the fiber fragment that constitutes multi-fibre district 28 is orientated along the longitudinal direction of fiber transition region 22 usually.
Fig. 3 is the microphoto of the bondedfibre fabric 10D that cutd open along 2A-2A line among Fig. 2.First bossing 16 that Fig. 3 shows partly links to each other with background by fiber transition region 24.As can be seen, multi-fibre district 32 contiguous few pars fibrosas 30.A large amount of fiber ends 26 that the multi-fibre district is 32 li have confirmed that the fiber fragment is highly parallel in the multi-fibre district.
Fig. 4 is the microphoto of the fiber transition region 22 of the bondedfibre fabric 10D that cutd open along 4-4 line among Fig. 2.The multi-fibre district of numbering 28 expression fiber transition regions 22, and number the few pars fibrosa of 27 expressions.As can be seen, the fiber fragment of few pars fibrosa 27 is height parallelizations.Usually, the parallel degree of the fiber in multi-fibre district 28 is lower than the multi-fibre district 32 shown in Fig. 3.
Fig. 5 is the art up schematic diagram of the cross section of first bossing 16 that links to each other with background part 12 by fiber transition region 24.Fiber transition region 24 comprises a few pars fibrosa 30 and a multi-fibre district 32.As what above mentioned, multi-fibre district 32 has the basic weight that is higher than few pars fibrosa 30.The basic weight of first bossing 16 in Fig. 5 between the multi-fibre district 32 is consistent basically, and equals the basic weight of background part 12 substantially.
Fig. 6 is the microphoto of amplification plan view that is similar to the bondedfibre fabric of bondedfibre fabric 10B among Figure 1B.The background part 12 of second bossing, 18 both sides has similar micro-pattern through compiling.In this embodiment, the upper surface of second bossing 18 also has this similar pattern through compiling.The fiber that constitutes the bunchy of second bossing 18 is what to be twisted, and is mutually to rely on twisting, and along being parallel to each other substantially on the longitudinal direction of bossing.
As what above mentioned, the basic weight of second bossing 18 is greater than the basic weight of background part 12.The density of second bossing 18 density with background part 12 substantially is identical.Second bossing 18 links to each other with background part 12 by fiber transition region 34, and the transition region basic weight is lower than the basic weight of background part 12.
Fig. 7 is the microphoto of the bondedfibre fabric that cutd open along 7-7 line among Fig. 6.A large amount of fiber heads 36 proofs that can see at second bossing 18, the fiber fragment of second bossing 18 are that the longitudinal direction along bossing stretches.
Fig. 8 is the art up schematic diagram of the cross section of second bossing 18 that links to each other with background part 12 by fiber transition region 34 of expression.As can be seen, the lower surface 12a of the lower surface 18a of second bossing 18 and background part 12 is coplanar basically.The top surface 18b of second bossing 18 is higher than the upper surface 12b of background part 12.
Fig. 9 is that expression uses supporting member of the present invention to produce the block diagram of each step in the bondedfibre fabric method.The first step of this method is that fiber web is placed (frame 1) on the profile supporting member.Fiber web be through soak in advance or after placing this supporting member with water-soaked (frame 2) to guarantee that it is still stayed on the supporting member when fiber web is processed.Be placed with above fibroreticulate supporting member from a series of hole below by, from each hole mesohigh fluid, as water, towards fibroreticulate upper surface, i.e. the surface that does not contact on this web surface (frame 3) with the profile supporting member.Preferred fluid is a water.Preferably water is taken out (frame 4) from supporting member with vavuum pump.With fiber web dehydration (frame 5).To take off the forming fabric of water and take (frame 6) away from supporting member.The fabric of moulding is passed through from a series of drying drum, so that fabric drying (frame 7).Then fabric is done back processing or done other processing (frame 8) as required.
Figure 10 is to use supporting member of the present invention to produce one type schematic representation of apparatus of bondedfibre fabric.In this device, the conveyer belt 70 of a porous ceaselessly moves around two discerptible live-rollerss 71 and 72.This conveyer belt is driven, so that it can circulate, or does clockwise or motion counterclockwise.Sparge pipe 74 is arranged on the top of the ascender 73 of conveyer belt 70.The eye or the hole 74a that have some very small diameter on this sparge pipe.The diameter in these holes is about 0.007 inch, has about 30 such holes on the per inch lineal measure.Under pressurized conditions, water is transported to sparge pipe 74, and from the hole, sprays with nondispersive jet or the line form that is substantially needle-like.Profile supporting member 75 is placed on the top of conveyer belt 70, and fiber web 76 is placed on the top of this profile supporting member.Suction tube 77 is arranged on over against the below of sparge pipe 74, but below conveyer belt 70 ascenders.This suction tube helps to remove the water of ejection from water pipe 74, in order to avoid flood fiber web 76.The water that is transported in the sparge pipe with predetermined pressure sprays from the hole of sparge pipe with line or the pattern that is substantially needle-like, and impacts the upper surface of fiber web 76.Enough short from the lower surface of sparge pipe 74 to the distance of the upper surface of processed fiber web 76, can be with the current of guaranteeing from the hole of sparge pipe 74, to spray with the above-mentioned upper surface that is substantially the non-dispersive form contact fiber web 76 of needle-like.This distance can change, but about 0.75 inch usually.Current flow through fiber web, flow through the osculum that is arranged on the profile supporting member then.The useless water of handling is removed by suction tube.As what can expect, have fibroreticulate profile supporting member as required can be repeatedly from sparge pipe below by, to produce fabric of the present invention.
Figure 11 has provided a kind of device that uses supporting member of the present invention to produce bondedfibre fabric continuously.Device among Figure 11 comprises a conveyer belt 80, and in fact it play a part the profile supporting member among the present invention.As well known in the art, conveyer belt is around the motion counterclockwise continuously of a pair of roller that separates.Be provided with fluid jet pipe 79 above conveyer belt 80, playpipe links to each other with some manifolds or nozzle sets 81.Each group has the very little hole of a row or multi-row diameter, and the diameter in each hole is about 0.007 inch, and 30 this holes are arranged on the per inch length.Water is to be transported in the nozzle sets 81 with predetermined pressure, and with very thin, the non-dispersive line or the pattern that are substantially needle-like spray from the hole.Pressure gauge 88 and control valve 87 are housed to regulate the pressure in every row or the every group of hole on the sparge pipe.Below each nozzle line or nozzle sets, be provided with a suction box 82, to remove unnecessary water and to guarantee that this zone avoids unsuitable and flood.To remain to be made fabric webs 83 of the present invention and deliver to profile supporting member conveyer belt.By a suitable shower nozzle 84 water is sprayed on the fiber web, the fiber web 83 of prewetting into also help when fiber web from the fluid jet pipe down through the time control fiber web.Pick trough 85 is arranged on below this fountain head so that remove unnecessary water.Fiber web in the counterclockwise direction from the fluid jet pipe below by.The operating pressure of any nozzle sets 81 can be independent of the pressure of other nozzle sets 81 and set.But, general operating pressure from the nearest nozzle sets of shower nozzle 84 is lower, for example is 100PSi.Like this, the fiber web that helps to come in drops on the surface of supporting member.When passing through in the counterclockwise direction in Figure 11 along with fiber web, the operating pressure of nozzle sets 81 can increase usually.And nonessential be the operating pressure that the operating pressure of each continuous nozzle sets 81 is higher than another nozzle sets that is adjacent in the clockwise direction.For example, the pressure operation that two or more adjacent nozzles groups 81 can be identical, after this, below continuous nozzle sets 81 (in the counterclockwise direction) with different pressure operations.Modally be the operating pressure the when operating pressure in the place that the terminal fiber web of conveyer belt is removed is higher than fiber web and has just entered conveyer belt.Though figure 11 illustrates 6 nozzle sets 81, this numeral is not crucial, but depends on hole row's number in the fiber web weight, speed, used pressure, every group etc.After pass through between fluid jet pipe and the suction tube, the bondedfibre fabric of being produced passes through from another pick trough 86 again, to remove unnecessary water.Distance from the lower surface of nozzle sets 81 to the upper surface of fiber web 83 is generally the 0.5-2 inch; Distance be 0.75～1.0 inch better.Clearly, fiber web can not closely arrive the stage of contact playpipe.On the other hand, if the distance between the lower surface of nozzle and the fiber web upper surface is excessive, the fluid line can be lost energy, and the efficient of handling can reduce.
A kind of device that uses supporting member of the present invention to produce bondedfibre fabric has been shown among Figure 12.In this device, the profile supporting member is that this cylinder of a rotary drum counterclockwise rotates.Cylinder 90 can be a continuous tubular cylinder or the outer surface that is made of cylinder some arcs 91.Under each situation, be that the outer surface or the outer surface of arc 91 by cylinder 90 constitutes desired profile supporting member shape.Peripheral part at cylinder is provided with the sparge pipe 89 that links to each other with some pore areas 92, is used for adding water or other fluid to the fiber web 93 that is placed on the arc outer surface.Each pore area can comprise the hole or the eye of the above-mentioned type that a row or multi-row diameter is very little.Usually the diameter in these holes is about the 5/1000-10/1000 inch.Nearly 50-60 hole arranged on the per inch length, if necessary also can be more.Water and other fluid hole row that flows through.Generally, as above show described, the pressure of each Kong Zuzhong normally from fiber web from its below by first group increase to a last group.Pressure monitors by 97 controls of suitable control valve and by pressure gauge 98.Cylinder links to each other with a groove 94, and a vavuum pump also is housed on this groove, anhydrates and guarantees that this zone avoids dipping so that remove.As shown in figure 12, in operation, fiber web 93 was placed on the upper surface of profile supporting member before sparge pipe 89.Fiber web from pore area below by and make bondedfibre fabric of the present invention.The fabric of moulding by the part 95 of this device, does not have pore area on this part again, carries out continuously but vacuumize always.Fabric takes off from cylinder in dehydrated back, and makes its drying by a series of dryings 96.
In order on bondedfibre fabric of the present invention, to produce bossing, the slight fiber web that tangles of one deck fiber or one is placed on the profile supporting member of a porous, and this supporting member comprises a upper surface with profile pattern and away from second surface of supporting member upper surface.Second surface produces bossing by the background part of upper surface generation fabric.
Have the structure that is displaced sideways that reduces the pristine fibre net on the upper surface, this sidesway can produce unfavorable high and low fibre density areas.If the work in-process fiber has excessive sidesway, have thin spot or fiberless zone on the resulting bondedfibre fabric.
Figure 13 illustrates a kind of example that is used for partly producing the profile supporting member of pattern at the background of bondedfibre fabric.Supporting member 102 comprises main body 100, and it has a upper surface 103 and a lower surface 104.According to predetermined pattern the protruding peak 105 that one row is separated by trench 106 is set on upper surface 103.On supporting member 102, some osculums 107 that pass supporting member thickness are set by certain figure.In this embodiment, each osculum 107 is centered on by 6 protruding peaks 105 and 6 trench 106.
Osculum 107 be taper or " the clock degree of lip-rounding ", at the diameter on the upper surface 103 greater than the diameter on lower surface 104.By the formed angle 111 of cone relatively the thickness 112 of supporting member 102 controlled, to produce ideal results.For example, if this angle is too big, the hole will be too little, so drainability is just not enough.If this angle is too little, on supporting member, just have only seldom or do not have protruding peak and trench.
On the pattern that repeats, the center distance S in adjacent hole equally also is important.Protruding peak 105 and trench 106 are produced by taper, slightly tapered osculum 107 intersections.If intersecting greater than the maximum gauge of osculum 107 at upper surface 103 places, can not appear in the center distance S in these holes, and supporting member will have smooth, flat upper surface, and the through hole of taper is arranged.When the center distance S in these holes less than along the hole in the heart during the diameter in the hole that records of line, conical surface intersects and forms recess.Supporting member among Figure 13 can partly produce similar to the compilation case at the background of textiles of the present invention.But, any pattern all can be used for the design of the background part of moulding bondedfibre fabric.
Second face of porous supporting member is made of some depressions, is recessed on the finished product fabric by these and produces bossing.Figure 14 A is the cross-sectional view of supporting member 122, and it has a upper surface 123 and second surface 124 that is made of sunk part 121.Hole 127 is substantially perpendicular to supporting member, and 104 passes completely through supporting member from upper surface 103 to lower surface.Must there be suitable size and quantity in these holes, so that removing unnecessary fluid in winding process, and avoid " undue dipping " supporting member in winding.
One skilled in the art will readily appreciate that sunk part 121 necessary enough sizes, so that on the finished product bondedfibre fabric, can produce boundary bossing clearly.For example, has the repeat patterns that constitutes around 6 protruding peaks 105 by an osculum 107 at the supporting member shown in Figure 13 102.The hole of osculum 107 is in the heart apart from being S on the supporting member 102.The minimum dimension of sunk part 121 must be greater than this hole in the heart apart from S.If in the heart apart from S, on the finished product bondedfibre fabric, bossing is with not obvious, or not existence less than the hole for the minimum dimension of sunk part 121.In the embodiment of the supporting member 122 that once is used to produce bondedfibre fabric of the present invention, the width of sunk part 121 is about 11 times of osculum 107 centre-to-centre spacing S.Sunk surface should be enough dark, is not to be in different planes so that can obviously debate, and also a plurality of planes can be arranged, and can be the peace of arc.Can there be the pattern identical with upper surface 123 on second surface 124 of the depression of supporting member 122, or has different patterns.
Upper surface at supporting member is provided with enough structures, and the motion with controlling fiber prevents " washing out " district, makes fiber web have enough activity to make simultaneously and himself drop in the depression and under the fluid jet effect to interweave.For hole with suitable aggressive tack pattern, structure that need not be other.But, on this surface, still be provided with some structures usually, so that handle the motion of fiber better and give finished product fabric visual sense of beauty.
Transition region between two planes is tangible.Can be thinning in the marginal portion of background fibre density, and in the corresponding increase of marginal portion fibre density near bossing.Length is parallel to the transition curve longitudinal direction, be 1/2 inch of the length of center cutting with the highest and minimum fiber density region, wide is that the averag density of the sample cloth of 7/64 inch cloth is 2.19 oz/yd 2, the rerouting bar of four kinds of different patterns is 1.53: 1 with the average weight ratio of light cloth.Consequently, its width characteristics is the basic weight that the basic weight of background part equals bossing substantially, but the relatively poor transition region of moulding has light and heavy part.In order to remedy this defective, preferred embodiment should have three or more clearly, substantially parallel surface, each surface is on the different levels of reverse part thickness.
Figure 14 B represents the cross section of profile supporting member 128, and it has a upper surface 123,124, the second recesses 125 in 121, the second surfaces of sunk part and lower surface 126.The whole thickness of supporting member is passed in hole 127.
A kind of bondedfibre fabric of being made by supporting member 122 comprises background part 12, first bossing 16 and the fiber transition region 24 that is made of few pars fibrosa 30 and multi-fibre district 32.The multi-fibre district 32 of fiber transition region 24 near and link to each other with first bossing, 16 peripheries.In this embodiment, have between few pars fibrosa 30 and the background part 12 one clearly, obvious visible boundary line.But, the boundary line around the multi-fibre district 32 and first bossing 16 is more unintelligible also not too obvious.Adopting the profile supporting member shown in Figure 14 B to make bondedfibre fabric can make a back boundary line become more clear, obvious.As shown in Figure 14B, profile supporting member 128 comprises a upper surface 123, second surface 124, a pair of second recess 125, lower surface 126 and passes the hole 127 of its thickness.Figure 15 illustrates the profile of the bondedfibre fabric that produces by profile supporting member 128.As can be seen, bondedfibre fabric comprises background part 12, first bossing 16 and is connected the fiber transition region 24 of background part and bossing.Similar to the situation of Fig. 5, fiber transition region 24 comprises few pars fibrosa 30 and multi-fibre district 32.For the bondedfibre fabric among Fig. 5, the upper surface in multi-fibre district 32 basically with the upper surface copline of first bossing 16, but the upper surface in the multi-fibre district 32 of the bondedfibre fabric in Figure 15 is on the plane on the upper surface of first bossing 16.This is because be provided with on supporting member 128 due to a pair of second recess 125.On the bondedfibre fabric shown in Figure 15, the boundary line between the multi-fibre district 32 of fiber transition region 24 and first bossing 16 is more clear than the similar boundary line of the bondedfibre fabric shown in Fig. 5, as seen.Recess other on the supporting member can produce other bossing on fabric.If necessary a plurality of concave surfaces can be set on supporting member, so that on bondedfibre fabric, produce more bossing accordingly.Clearly, in accordance with the teachings of the present invention, can provide a kind of supporting member, be used for making the pattern generating of the bondedfibre fabric of Figure 15 to change, wherein, also have a bossing that raises up by its upper surface at the middle part of first bossing 16.
Referring to Figure 1B, it shows a kind of bondedfibre fabric again, and second bossing 18 of rectangle is arranged above.As what said, the basic weight of second bossing 18 is greater than the basic weight of background part 2.Bondedfibre fabric among Figure 1B can be made by improving the supporting member 128 shown in later Figure 14 B.This improved supporting member will comprise second recess 125 that is designed to desirable rectangle, but not comprise sunk part 121 or its second surface 124.
Profile supporting member of the present invention is produced in the original supporting member work that can be on device shown in Figure 16 has any profile by processing.
Desirable original workpiece is installed on the suitable axle or rod 821, is fixed, and it is rotated around its longitudinal axis on bearing 822 with tubular.Provide a rotating driving device 823, with the speed drive axle 821 of control.Rotational pulse generator 824 is connected with axle 821, is used to monitor the rotation of axle, so that all know its radial position at any time.
In the mode parallel with this one or more guide rails 825 are installed in axle 821 rotation peripheries, this guide rail makes balladeur train 826 move on the whole length of axle 821, keeps a stable gap with supporting member 802 upper surfaces 803 simultaneously.Skid actuating device 833 drives balladeur train along guide rail 825, simultaneously by the lateral position of balladeur train impulse generator 834 monitoring balladeur trains with respect to supporting member 802.Focusing arrangement 827 is housed on the balladeur train.Focusing arrangement 827 is contained on the focusing guide rail 828 and makes it perpendicular to balladeur train 826 motions, and a condenser lens 829 with respect to upper surface 803 is set.Focusing drive device 832 is set with location focusing arrangement 827 and adjust the focal length of condenser lens 829.
Condenser lens 829 is fixed in the tube connector 830 of focusing arrangement 827, and tube connector 830 has to it introduces compressed-air actuated device, with cooling and maintenance condenser lens 829 cleanings.
Terminal refraction of optical beam mirror 835 also is housed on balladeur train 826, by it laser beam 836 guiding condenser lenses 829.Laser instrument 837 is located at a distance, by suitable refraction of optical beam mirror 838 with the terminal refraction of optical beam mirror 835 of laser beam direction.Although also can be directly installed on laser instrument 837 on the balladeur train 826 and cancel refraction of optical beam mirror, because limited space and is connected laser instrument and uses jockey to make that installation is more desirable at a distance.
When giving laser instrument 837 energisings, the laser beam of launching 836 is reflected away by refraction of optical beam mirror 838 earlier, again by terminal refraction of optical beam mirror 835 reflections, beam direction condenser lens 829.The laser beam path is to constitute like this, if condenser lens 829 is removed, light beam can be by the longitudinal centre line of axle 821.
When laser beam 836 passed through from condenser lens 829, lens were the place of concentration of energy at close beam center.Ray is not to turn to by a single point, but by the point of minor diameter it is turned to.The point of minimum diameter is called as focus.Focus is in apart from lens certain distance part, makes a distance be called as focal length.The size of the luminous point that records on the distance that is shorter than or is longer than focal length all can be greater than smallest spot.
Make or obtain to comprise predetermined profile and the original supporting member of the predetermined pattern of some openings on it with other form.At US-5, a kind of being suitable for as this original supporting member disclosed among Fig. 3 of 098,764.Number 56 among Fig. 3 of this supporting member is in patent ' 764, have pyramid in a row 61, its pinnacle 65 on orthogonal both direction, to align above it.These pyramids have " side " 66, and the gap between the pyramid is called as " recess " 67.This supporting member also comprises some hole or eyes of arranging with definite shape 68, and the thickness of supporting member is passed in these holes.At US-5, the supporting member of several other shapes is also disclosed in 098,764, all these supporting members all are suitable for as the orginal of making the supporting member that uses among the present invention.Original supporting member must be to be made by the material that is suitable for laser ablation process; Acetal or acrylonitrile materials are adoptable ideal materials.The details of laser treatment polymeric material is at the United States Patent (USP) U.S.Patent of common transfer No.5,585,017, be entitled as in " Defocused LaserDrilling Precess For Making Fafric Forming Device " on the booksly, it is used as reference of the present invention.
Be used as original profile supporting member at the supporting member shown in Figure 13, make the supporting member of the bondedfibre fabric 10C that is used for shown in the production sketch 1C by it.This original supporting member is shown in United States Patent (USP) UA5, and among Fig. 5 of 670,234, the content disclosed in this patent also is used as reference of the present invention.As disclosed in above-mentioned patent, this supporting member can be used for producing and has similar first textiles through unofficial sight.
Tell about below original supporting member is carried out laser boring can be used for the bondedfibre fabric 10C shown in the production sketch 1C with manufacturing supporting member of the present invention.Must carry out an initial focus steps.Original supporting member shown in Figure 13 is fixed on the axle 821, starts skid actuating device 833, the focus of condenser lens 829 is transferred to the non-perforation of the original tube that is used to make original supporting member.Usually, non-perforation is as the edge of each end of supporting member; These non-perforations not only are provided for testing the zone of engraving, and play the effect of stiffening device, thereby make supporting member have structural intergrity.Laser is pulsed simply, and axle is paused to rotate between pulsation, to produce a series of little recesses.
Focusing arrangement 827 moves to change the focal position and to produce other recess relative to axial line subsequently.Along with focusing arrangement reciprocating motion between two rows, on base material, can get 20 recesses of the 20 every rows of row.Recess is carried out micrography, and find out that minimum row of depression.Position when focusing arrangement 827 is got this row's minimum diameter recess has constituted the respective diameters that light beam focuses on the original supporting member upper surface 103.
Select desirable pattern, pattern as shown in Figure 17 A.Figure 17 A is the dot chart that is used to make the pattern of supporting member, and the supporting member of manufacturing is used for the bondedfibre fabric 10C shown in the production sketch 1C at last again.Figure 17 B is the dot chart that the high power of the square part 301 among Figure 17 A is amplified.Shown in Figure 17 B, the arch section of the mirror image of letter " S " is not level and smooth arc, but a series of small step shape square or " pixel ".Each pixel is corresponding with the lip-deep position of original supporting member to be carved.The general size of the corresponding pixel in supporting member surface is 0.002 inch on each direction.Dyed black and the corresponding pixel in position that will become depression on final supporting member, promptly laser instrument is opened the position of removing material by ablation.White pixel is corresponding with the position that remains unchanged on this processing supporting member, is the pent position of laser instrument therefore.Encode the by this way laser operation instruction of the pattern of Figure 17 A is so that produce figure on supporting member.
In order to produce the figure of ideal dimensions, must adjust pattern.For example, be 1 inch depression if need length on the supporting member, and adopt above-mentioned size that it is long that the figure of the dot chart that is produced is necessary for 500 pixels.
Select the position of first recess that will on original supporting member, make then.This will constitute lengthwise position (perpendicular to the end face of supporting member precursor) and circumferential position (around original supporting member).The upper left corner of dot chart is corresponding shown in this home position and Figure 17 A.Position around line of pixels on the dot chart and the original supporting member is corresponding.Pixel column in the dot chart is with corresponding perpendicular to the position of original supporting member end face.
If on final supporting member, need more than one recess, set up an original angle position for each this recess.If necessary, can dispose computer control system, the repeat number of (vertically and circumferentially) pattern so that on clear and definite each direction, and determine the starting point of each repetition by computer.Operation at each recess is repetition.
In operation, balladeur train is driven earlier, so that the focus of lens is corresponding with previous first recessed position of determining.This position is determined by balladeur train impulse generator 834.
Axle is rotated with stable speed.Circumferential position is determined by rotational pulse generator 824.The actual speed that is adopted depends on the laser energy, required depth of cut, laser spot size and at every turn rotate the process of balladeur train.In case axle is in operating rate, the leftmost row of COMPUTER DETECTION dot chart sends the laser instrument indication.If not black pixel on this row, laser instrument keeps cutting out in the first whole process of changeing of axle.If on first row black picture element is arranged, laser instrument is opened when position relative with black picture element on the supporting member is in the focus place of lens.The instruction of coding causes the laser operations of the repetition around supporting member on the left side one row, produces the pattern that repeats in each specific region.
After having changeed a whole circle, skid actuating device is positioned at next position that will remove material on the original supporting member by laser ablation process to the focus of lens again.This reposition just in time on original supporting member with dot chart in second row's pixel corresponding site above.This reposition is confirmed by balladeur train impulse generator 834.The coded command of second row's pixel in the system of battle formations of computer checkpoint then, and in the rotation next time of axle, make laser instrument by the instruction opening and closing.Repeat this process, " burning is " on original supporting member up to pattern of pixels quilt whole on the dot chart.
Should be noted that in said process, each through on material, producing some narrow cut channels rather than bigger depression.Because these cut channels are to be arranged side by side accurately and partly overlapping, general effect be a wide depression greatly.Produce smooth pattern, need be in design with the corresponding position of single pixel less than the minimum laser spot size that is adopted.This can make adjacent two passages overlapping and cause the mixing of each channel edge, thereby " sawtooth " dwindled.For certain purpose, usually by the square pixel of being more convenient for adopting inequality proportion.For example, can adopt rectangular pixels.
Cup depth is directly proportional with energy, and is inversely proportional to the process of rotating speed and revolution balladeur train.The general effect of a plurality of passages is wide depressions, and the end of overlap channel lumps together.This process can repeat repeatedly to produce big pattern effect as required on the working face of supporting member.
Darker if desired depression produces second kind of pattern, and is corresponding with the pixel that will be engraved as different depth, also will carry out identical processing, but or adopt higher laser can or the lower degree of depth of rotating speed to obtain increasing.
The above-mentioned laser ablation process that original supporting member is done has surprising, interesting situation.Different with the lathe turning operation, turning is removed a constant degree of depth to material, and laser ablation above-mentioned is removed the material of a fixed qty from original supporting member.For example, in said process, original supporting member comprises profile pattern shown in Figure 13.Laser ablation process subsequently produces the corresponding recess of mirror image with letter " JSK ".When adopting final supporting year to make bondedfibre fabric, letter " JSK " appears at the bossing of fabric.As can be seen, wherein letter " JSK " constitutes first bossing of bondedfibre fabric 10C to this point in Figure 16.The letter of these projectioies " JSK " has the similar outward appearance through compile identical with background part 12.
The specific embodiment
Example 1
This embodiment has provided the production process of the profile supporting member that can be used for bondedfibre fabric 10C shown in the shop drawings 1C.Original profile supporting member is made by acetal, and has peak shown in Figure 13, the profile pattern in recess and hole.Original profile supporting member is handled by laser boring and is made, this method is documented in the United States Patent (USP) U.S.Patent No.5 that awaits the reply of ordinary license, 585,017, _ _ in, the name of this application is called " Defocused Laser DrillingProcess For Making Fabric Forming Device ", and disclosed file is used as reference here.The supporting member of example 1 adopts above mentioned original supporting member and above-mentioned laser ablation methods to make on device shown in Figure 16.This original supporting member is installed on the axle 821.Be used to control the computer graphics figure of laser ablation process shown in Figure 17 A.Setting laser can be 1320 watts to produce a stable power output.Condenser lens 829 is the positive meniscus lens, and focal length is 5 inches.The focus of condenser lens 829 is transferred to the upper surface of marginal portion of the end engraving of profile supporting member.This is consistent with the reference diameter of above carrying the original supporting member of being established.In laser ablation process, axle 821 rotating speed is 35rpm, is the 69m/ branch in the speed of supporting member upper surface.The revolution coaster advances 50 microns.Laser ablation process lasts till that the whole outer surface of original supporting member is all become desirable figure by laser engraving.Resulting profile supporting member comprises first pattern and second pattern that is positioned under first pattern near its outer surface, that is, and and the degree of depth of recessed supporting member.First pattern on the gained supporting member is a pattern shown in Figure 13.Second pattern, the pattern that promptly is positioned at the recessed supporting member degree of depth under first pattern is a pattern shown in Figure 17 A.
Example 2
This embodiment has provided the method for the bondedfibre fabric 10C shown in the profile supporting member production sketch 1C that utilizes example 1 manufacturing.The profile supporting member of example 1 is taken off and is installed on the cylinder 90 of device shown in Figure 12 by the axle 821 from device shown in Figure 10.
By 0.6 oz/yd of making through traditional carding process 2100% web and 0.6 oz/yd of making through traditional air-laid process 2100% web merges, and making the weight that all is made of the staple length cotton fiber is 1.2 oz/yd 2Fiber web.In mentioned example.Be placed on by net air lay carding net above make the two merging.Be appreciated that if necessary, the net that is carded to also can be placed on net that air-flow becomes above.
Adopt conventional flat rubber belting winding device to make above-mentioned 1.2 oz/yd 2Pre-entanglement that 100% web is slight, described device comprises 18 pore areas, these pore areas are being separated from each other on the machine direction of device and are launching on the width of device.The diameter in hole is 0.007 inch.30 holes/alignment inch is arranged on every pore area.The entanglement fluid is a water.From the updrift side to the downstream direction, supply water to 3 pore areas with the pressure of 200psig; Pressure with 1000psig supplies water to last 12 pore areas.Pre-winding device is with the speed operation of 330fpm.The web that processes is dry on steam drum, and 100% web slightly to be tangled is hereinafter referred to as " preceding combination ".
Two-layer above-mentioned preceding combination is used to make first textiles 10C.Combination before two-layer is placed on the profile supporting member that is installed in the example 1 on the axle 821 in advance.Water is sprayed on this two-layer preceding combination a little then.From the distance to preceding bond material top bottom the pore area of device shown in Figure 12 is 0.75 inch.Only there is one to be used to above-mentioned procedure of processing in 5 pore areas 92 shown in Figure 12.Before two-layer combination with 100 yards/minute speed from this pore area 1 through once, the pressure with about 600psig supplies water to pore area simultaneously.Then, preceding combination again under the pore area through 8 times.Is 100 yards/minute at these 8 times through out-of-date linear speed, and the pressure that supplies water to pore area is 1600psig.The bondedfibre fabric 10C that is produced will carry out vacuum dehydration, takes off and does quick-fried hot bellows from supporting member.
As can be seen, bondedfibre fabric 10C comprises having similar background part 12 through unofficial sight, and this part is that pattern is corresponding shown in described first pattern and Figure 13 by first pattern generating on the supporting member.The bossing 16 of bondedfibre fabric 10C is by pattern generating shown in Figure 17 A.
The further details that is used to produce the relevant apparatus of bondedfibre fabric of type disclosed herein and method is seen the United States Patent (USP) U.S.Patent No.5 of ordinary license, 674, " Apparatus For Making Nonwoven Fabrics HavingRaised Portions, " disclosed content is used as reference here 591. name is called.
Basic weight is measured by following method.With detected materials damping at least 6 hours under 70, the condition of relative humidity 65%.With the specimen of known stamping bed from die-cut following 3 predetermined areas of the desired site of humidity adjusting material.This area is 30 square millimeters.The specimen that each is die-cut is placed on the analytical balance weighs.Weight is removed the basic weight that just obtains each specimen by area.With the mean value of sample basic weight on three as the basic weight that will survey.
Although several examples of the present invention and variation have been done detailed description here, those skilled in the art can be according to the open and many improved designs of instruction proposition of the present invention obviously.

Claims (14)

1. produce the method for bondedfibre fabric, comprise the following steps:
One fibrage is positioned on the peak of cylindrical configuration supporting member;
Spray its adjacent fluid bundle facing to fibrage simultaneously, spray facing to the peak then, fluid passes aperture subsequently;
When fluid sprays facing to fibrage, the rotating cylinder supporting member;
The injection fluid of aperture is passed in removal; Take out bondedfibre fabric from the surface of supporting member;
Described profile supporting member is used for producing the bondedfibre fabric with at least one bossing, is formed by the method that comprises the following steps:
A) provide a workpiece;
B) on the upper surface of workpiece, form the first minute sized profile pattern;
C) form the perforate that some pass described workpiece;
D) at least one the large scale region overlapping that caves in from described upper surface on described workpiece.
2. method according to claim 1, wherein said sunk surface have the second minute sized profile pattern.
3. method according to claim 2, the wherein said first and second profile patterns are identical.
4. method according to claim 1, the step of the wherein said formation first profile pattern comprises with laser punches on the upper surface of described workpiece.
5. method according to claim 4, wherein said laser boring step are included in mobile laser beam on lip-deep a series of raster scanning lines of workpiece.
6. method according to claim 4, the step in wherein said overlapping at least one large scale zone comprise the laser desired depth of ablating under described upper surface.
7. method according to claim 6, wherein said laser ablation step are included in mobile laser beam on a series of raster scanning lines on the upper surface of workpiece.
8. method according to claim 1, the step in wherein said overlapping at least one large scale zone is included in the step that forms two or more described zones under the upper surface with the different degree of depth.
9. method according to claim 1, the step in wherein said overlapping at least one large scale zone are included in first type surface and the one or more subsurface that is different from the depression of described first degree of depth that forms first deep recess under the upper surface.
10. method according to claim 9, one of them subsurface forms around described first type surface, and with certain depth depression, the width of subsurface is basically less than the width of described first type surface under described first degree of depth for described subsurface.
11. method according to claim 1, wherein step (b) and (c) finish by the following step:
A) focussed laser beam is so that its focus is under described workpiece surface:
B) punched the predetermined pattern of some tapered openings of described workpiece with the laser beam brill, on the upper surface of final supporting member, formed a series of peaks and paddy thus around each aperture.
12. method according to claim 11, the centreline spacing of wherein said adjacent holes is less than the full diameter of each adjacent holes epiconus.
13. method according to claim 12 wherein makes described peak and the paddy pattern-forming around bellmouth, so that a kind of similar bondedfibre fabric through compiling to be provided.
14. be used to produce the device of bondedfibre fabric, it comprises:
Rotating bored roll with a upper surface, the minute sized pattern that comprises several peaks, paddy and aperture on the surface, each described aperture has a conical top that is centered on by a series of described peaks and paddy, with at least one the microsize zone from the upper surface depression, described microsize zone has described microsize pattern on described region upper surface;
Be used for fibrage is placed on device on peak on the cylinder upper surface top;
Be arranged on the device in the cylinder outside, it is used for spraying adjacent fluid bundle simultaneously facing to described fibrage, sprays facing to peak on the upper surface and sunk area then, and fluid passes perforate and enters cylinder subsequently;
When described fluid is facing to hand hay cutter jet surface outside described, be used to rotate the device of described cylinder;
Be arranged on the device of cylinder inboard, be used for removing fluid from cylinder surface;
Be used for the device of bondedfibre fabric from the cylinder surface taking-up.
CNB001011669A 1994-09-16 2000-01-22 Method for producing non-woven fabrics Expired - Fee Related CN1253621C (en)

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US308017 1994-09-16
US08/308,017 US5674587A (en) 1994-09-16 1994-09-16 Apparatus for making nonwoven fabrics having raised portions
US308,017 1994-09-16

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EP0705933B1 (en) 2001-05-09
CA2158421C (en) 2006-10-10
EP0705933A2 (en) 1996-04-10
TW328975B (en) 1998-04-01
US5906786A (en) 1999-05-25
DE69520861D1 (en) 2001-06-13
EP0705933A3 (en) 1997-10-01
CN1277274A (en) 2000-12-20
CN1064728C (en) 2001-04-18
JP3739448B2 (en) 2006-01-25
USRE38105E1 (en) 2003-05-06
FI954357A0 (en) 1995-09-15
CA2158421A1 (en) 1996-03-17
DE69520861T2 (en) 2001-09-13
US5822833A (en) 1998-10-20
US5674587A (en) 1997-10-07
FI954357A (en) 1996-03-17
CN1132276A (en) 1996-10-02
JPH08176945A (en) 1996-07-09

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